Fire starter mixture and method of forming same

ABSTRACT

A fire starter mixture including at least about 10% and at most about 90% by weight of a biomass component, and at least about 10% and at most about 90% by weight of a fuel component. The fuel component includes at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel.

FIELD OF THE INVENTION

The present invention is a fire starter mixture and a method of forming same.

BACKGROUND OF THE INVENTION

Various fire starters are known. The known fire starters have a number of disadvantages, e.g., due to their composition, they tend to be relatively expensive. Also, the known fire starters are typically formed using processes and materials that are not environmentally friendly and sustainable.

SUMMARY OF THE INVENTION

For the foregoing reasons, there is a need for a fire starter mixture that overcomes or mitigates one or more of the disadvantages or defects of the prior art. Such disadvantages or defects are not necessarily included in those described above.

In its broad aspect, the invention provides a method of forming a fire starter mixture for use in igniting a fire. The method includes providing a biomass component and also providing a fuel component comprising at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel. The biomass component and the fuel component are mixed together to provide the fire starter mixture, which includes at least about 10% and at most about 90% by weight of the biomass component, and which also includes at least about 10% and at most about 90% by weight of the fuel component.

In another of its aspects, the invention provides a fire starter mixture that includes at least about 10% and at most about 90% by weight of a biomass component, and at least about 10% and at most about 90% by weight of a fuel component. The fuel component includes at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel.

In another aspect, the invention provides a method of forming a fire starter assembly including providing a fire starter mixture that includes at least about 10% and at most about 90% by weight of a biomass component, and at least about 10% and at most about 90% by weight of a fuel component. The fuel component comprising at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel. The fire starter mixture is positioned in an at least partially flammable container.

In another of its aspects, the invention provides a fire starter assembly including a container formed of at least partially flammable material, and a fire starter mixture. The fire starter mixture includes at least about 10% and at most about 90% by weight of a biomass component, and at least about 10% and at most about 90% by weight of a fuel component. The fuel component includes at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel. A predetermined amount of the fire starter mixture is positioned in the container.

In yet another of its aspects, the invention provides a method of igniting a fire in which a solid combustible fuel is consumed. The method includes providing the solid combustible fuel, and providing at least one fire starter assembly. The fire starter assembly includes a container formed of at least partially flammable material, and a fire starter mixture. The fire starter mixture includes at least about 10% and at most about 90% by weight of a biomass component, and at least about 10% and at most about 90% by weight of a fuel component. The fuel component includes at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel. A predetermined amount of the fire starter mixture is positioned in the container. The fire starter assembly is positioned at least partially below the solid combustible fuel. The fire starter assembly is then ignited.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood with reference to the attached drawings, in which:

FIG. 1 is a flowchart schematically illustrating an embodiment of a method of the invention;

FIG. 2 is a flowchart schematically illustrating an alternative embodiment of the method of the invention;

FIG. 3 is a top view of an embodiment of a fire starter assembly of the invention; and

FIG. 4 is a side view of solid combustible fuel with the fire starter assembly positioned under a portion thereof.

DETAILED DESCRIPTION

In the attached drawings, like reference numerals designate corresponding elements throughout. Reference is made to FIGS. 1 and 2 to describe an embodiment of a method of forming a fire starter mixture of the invention indicated generally by the numeral 20. As will be described, the method is for forming a fire starter mixture 22 for use in igniting a fire. The method includes the step (FIG. 1) of providing a biomass component 26 and a fuel component 28. As will be described, the fuel component preferably includes at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel. The biomass component 26 and the fuel component 28 are mixed together (step 29) to provide the fire starter mixture 22, which includes (i) at least about 10% and at most about 90% by weight of the biomass component 26, and (ii) at least about 10% and at most about 90% by weight of the fuel component 28.

As will be described, the biomass component 26 may include various materials. Also, the fuel component 28 may include various primary and secondary fuels, as will also be described. The primary fuel is flammable, and the secondary fuel is combustible. Preferably, the primary and secondary fuels are mixed in proportions that are economic, but also will provide suitable performance.

To form the fire starter mixture 22, the biomass component 26 and the fuel component 28 may be mixed in any suitable mixer (not shown). Those skilled in the art would be aware of suitable mixers, e.g., Forsberg, ribbon, drum, and paddle mixers. The operation of the mixing equipment may be batch or continuous, depending on production requirements.

The fire starter mixture 22 preferably is packaged or formed in any suitable manner.

For instance, in one embodiment, the fire starter mixture 22 preferably is packaged to form a fire starter assembly 33 (step 34). Any suitable packaging or container may be used. An embodiment of the fire starter assembly 33 of the invention is illustrated in FIG. 3.

When included in the fire starter assembly 33, the fire starter mixture 22 may conveniently and safely be used to initiate combustion of a solid combustible fuel “F”, e.g., wood or charcoal (FIG. 4). It will be understood that the wood may be in any suitable form, e.g., wooden logs, or wood chips or pellets. Similarly, the charcoal may be in any suitable form, e.g., charcoal briquettes. In FIG. 4, the solid combustible fuel “F” is illustrated as a pile of wooden logs for clarity of illustration, as an example only.

In one embodiment, the fire starter assembly 33 of the invention preferably includes a predetermined amount or quantity of the fire starter mixture 22 that is packaged in relatively small pouches “P” (FIG. 3), e.g., bags made of polyurethane or other suitable material, sized as required. For example, the pouches “P” may be made of polyethylene (PE), polypropylene (PP), polystyrene (PS), LDPE, HDPE, or of paper coated on its inner side with polyurethane, or wax or another suitable inner coating. Suitable sizes of the pouches may be, for instance, 4×6 inches, or 6×8 inches. Preferably, a predetermined amount (e.g., a predetermined mass) of the fire starter mixture 22 is positioned in the pouch “P”.

In one embodiment, the pouches “P” preferably are made of material that is flammable. Accordingly, in use, the fire starter assembly 33 may be ignited (e.g., using fire from a match, or any suitable ignition device) by first igniting the pouch “P”. It has been found that the fire quickly spreads from the pouch “P” to the fire starter mixture 22 inside the pouch “P”, and the fire starter mixture 22 is in turn quickly ignited by the burning pouch “P”. Once ignited, the fire starter mixture 22 preferably burns with sufficiently high flames, for a sufficiently long period of time, to ignite the solid combustible fuel “F”.

In summary, the fire starter assembly 33 preferably is formed by providing the fire starter mixture 22, and then positioning the fire starter mixture in an at least partially flammable container. For example, in one embodiment, the container may be the pouch “P”.

As will be described, a number of factors are taken into account in order to determine optimum proportions of the components of the fire starter mixture 22.

In one embodiment, the pouch “P” may be sealed or otherwise closed after the fire starter mixture 22 is positioned inside the pouch “P”. Those skilled in the art would appreciate that sealing the pouch “P” facilitates transportation of the fire starter assembly 33. Alternatively, the pouch of the fire starter assembly 33 may be any suitable partially flammable container, e.g., an open cup. It will also be understood that, in another alternative embodiment, the fire starter mixture 22 may be used and ignited directly, i.e., in the absence of a pouch “P”.

It will be understood that the fire starter mixture 22 may be used in any suitable manner, to ignite any arrangement of fuel. As illustrated in FIG. 4, the fire starter assembly 33, provided in a prepackaged form as described above, may be positioned partially underneath a pile of the solid combustible fuel “F”. Those skilled in the art would appreciate that the pile of solid combustible fuel “F” preferably is arranged so as to permit adequate oxygen to be provided to the fire at its early stages. Preferably, once the fire starter assembly 33 is in position at least partially underneath the suitably arranged pile of combustible fuel “F”, the pouch “P” containing the fire starter mixture 22 is ignited, i.e., the fire starter assembly 33 is ignited.

It is preferred that only a relatively small amount of the fire starter mixture 22 is provided in each pouch “P”. For example, in one embodiment, the amount of fire starter positioned in each of the pouches “P” preferably is approximately 30 grams to 100 grams.

Those skilled in the art would appreciate that the amount of the fire starter mixture 22 that is needed would depend on a number of parameters, e.g., the type of solid combustible fuel “F”, and its condition. For example, it has been found that, where the fuel “F” is relatively “wet” wood, approximately 100 g. of the fire starter mixture 22 may be required in the pouch “P”. However, if the combustible fuel “F” is relatively dry, then only approximately 30 g. of the fire starter mixture 22 may be needed in the pouch “P”.

It will be understood that, accordingly, the fire starter assembly 33 may be provided with different amounts of the fire starter mixture 22 in the respective pouches “P”. For instance, the fire starter assembly 33 may be available in which the predetermined amount of the fire starter mixture 22 therein is 30 g., 100 g., and a suitable intermediate amount.

As is known, the energy content of certain fuels may vary, depending on a number of variables. For instance, if wood is relatively wet, its energy content (e.g., expressed in BTUs per lb.) is lower than similar wood that is dry.

The approximate energy contents of various materials are set out in Table 1 below.

TABLE 1 Material BTU/lb (approx.) Wet wood 4000 Dry wood 7000 Ethanol 12800 Kerosene 19300 Methanol 9900 Vegetable oils 21000 Bio Diesel 16000 Waste Paper/cardboard 6500 Recycled Coffee  8000-10000 AO C12/C14 18400-17600 Iso-propanol(IPA) 12960 Fatty Acid Residues 12500-14000 Wood Shavings 3850 Pine Bark 9200 Hard Wood 8400 Wood 7870

It is preferred that the fire starter mixture 22 of the invention has a relatively high energy content (BTU/lb.), sufficient to vaporize moisture in the wood at the point of contact, resulting in rapid initiation of combustion of the solid combustible fuel “F” by the fire starter mixture 22, i.e., when the fire starter assembly 33 is ignited. In addition, the flames from the burning fire starter mixture 22 preferably are sufficiently high, and of sufficient duration, to initiate combustion of the solid combustible fuel “F”.

In one embodiment, the biomass component 26 preferably is selected from the group consisting of dried coffee grounds, cellulosic material, and combinations thereof. For instance, in one embodiment, it is preferred that the biomass component 26 includes cellulosic material to the extent of between approximately 100% and approximately 10% by weight of the biomass component, and dried coffee grounds to the extent of between 0% and 90% by weight of the biomass material. In another embodiment, the biomass component preferably includes dried coffee grounds to the extent of approximately 50% by weight of the biomass component and the cellulosic material to the extent of approximately 50% by weight of the biomass component.

As will be described, the filter paper and the cups preferably are processed further, and separately from the coffee grounds, to provide the cellulosic material. It will be understood that the cellulosic material may be made out of various items. For example, in an alternative embodiment, the cellulosic material preferably includes filter paper and cardboard. Those skilled in the art would appreciate that the cardboard may be coated (e.g., with wax, PE, PP, LDPE, or HDPE) or uncoated. Coatings may include natural waxes fully or partially hydrogenated from various oils and fats from plant or animal origins, and also may include petroleum or synthetic waxes.

Preferably, the dried coffee grounds are made from coffee shop waste 140 including coffee grounds 142 and filter paper and cups 144, by (i) screening the coffee shop waste, to separate the coffee grounds from the filter paper and the cups, and (ii) drying the coffee grounds, to form the dried coffee grounds. As described below, there may also be an initial pre-screening step, intended to remove any unwanted waste material.

Also, it is preferred that the filter paper and the cups are separated from each other and the separated filter paper is processed to provide the filter paper and the separated cups are processed to provide the cardboard.

It will be understood that the source(s) of the waste materials may be any suitable source(s). For instance, the coffee grounds may be produced by a retail coffee shop or similar establishment, i.e., the coffee grounds may be derived from waste materials therefrom. Similarly, the cellulosic material may be derived, at least in part, from the waste materials generated by a retail coffee shop.

Because a substantial proportion of the fire starter mixture 22 preferably is materials that would otherwise be considered waste, the fire starter mixture 22, if mass produced, would reduce the amount of the waste material sent to landfills or otherwise not reused or recycled. As will also be described, the coffee grounds and the cellulosic material have significant energy content, and their utilization in the invention contributes significantly to the fire-starting capability of the fire starter mixture 22.

The approximate energy content of various embodiments of the biomass component 26 of the invention are set out in Table 2 below.

TABLE 2 Ingredients Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 Test 10 Test 11 Biomass Mix % % % % % % % % % % % Coffee 0 10 20 30 40 50 60 70 80 90 0 Grounds Cellulose 100 90 80 70 60 50 40 30 20 10 100 (Biomass) BD 7.80 10.26 11.16 12.23 13.54 15.50 17.21 19.90 23.61 29.00 7.80 lbs/ftcubic (Dry) BTU/LB 7000.00 7988.80 8045.60 8102.40 8159.00 8216.00 8272.80 8329.60 8386.40 8443.20 7000.00 Dry BTU/LB 12766 14296 14126 13956 13786 13616 13446 13276 13106 12936 12766 Fuel Blend (Wet) fuel added Primary 0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00 Fuels (Isopar M ™) Secondary 100.00 90.00 80.00 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 Fuels (Recycled Oil)

Isopar M™ is an odorless kerosene product that may include C12 to C14. It is believed that any of C12-C18 would provide the same results as Isopar M™ in the tests tabulated in Table 2, due to BTU content of each being substantially the same. Other, similar products including C12-C14 (e.g., Isopar L™ and Linpar 1416V™) may be used as primary fuels. The Isopar L™ and Isopar M™ products may be obtained from Imperial Oil. The Linpar 1416V™ product may be obtained from Sasol. Those skilled in the art would appreciate that other linear alpha olefins may be suitable for use as primary fuels. For instance, those skilled in the art would be aware that C12 to C14 or similar products may be obtained from any suitable supplier, e.g., INEOS.

From the foregoing Table 2, it can be seen that the biomass component 26 with between 20% and 80% coffee grounds, and between 80% and 20% cellulose, has a relatively high energy content.

In view of the foregoing results, different formulations of the fuel component 28 were tested, with the biomass component 26 including approximately 50% coffee grounds and approximately 50% cellulose. These test results are summarized in Tables 3A-3C below. As noted above, various formulations of the biomass component 26 are suitable. It will be understood that the 50/50 formulation of the biomass component 26 was initially selected for testing solely for convenience.

The approximate energy contents of various embodiments of the fire starter mixture of the invention in which the formulation of the biomass component is 50% coffee grounds and 50% cellulose are set out in Tables 3A-3C below. Also, bulk densities for certain embodiments of the fire starter mixture are set out in Tables 3A-3C.

In Table 3A, the fuel component 28 tested includes 50% kerosene or odorless kerosene (e.g., ISOPAR) (the primary fuel) and 50% recovered/recycled corn oil (the secondary fuel).

TABLE 3A Test Test Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 10 11 Ingredients % % % % % % % % % % % Biomass 0 10 20 30 40 50 60 70 80 90 100 Mix (50/50) Fuel Blend 100 90 80 70 60 50 40 30 20 10 0 (50/50) BD 47.82 46.57 45.32 44.07 42.82 41.58 36.36 31.148 25.932 20.716 15.50 lbs/ftcubic (Wet) BTU/lb 21000.00 19721.00 18443.20 17164.80 15886.40 14608.00 13329.60 12051.20 10772.80 9494.40 8216.00 (Wet)

In Table 3B, the fuel component 28 tested is 50% kerosene, and 50% recovered corn oil.

TABLE 3B Test Test Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 10 11 Ingredients % % % % % % % % % % % Biomass 0 10 20 30 40 50 60 70 80 90 100 Mix (50/50) Fuel Blend 100 90 80 70 60 50 40 30 20 10 0 (50/50) BD 50.44 49.37 48.29 47.218 46.144 45.07 39.156 33.242 27.328 21.414 15.50 lbs/ftcubic (Wet) BTU/lb 20250.00 19046.60 17843.20 16639.80 15436.40 14233.00 13029.60 11826.00 10622.80 9419.40 8216.00 (Wet)

In Table 3C, the fuel component 28 tested is 50% biodiesel (the primary fuel), and 50% recovered corn oil (the secondary fuel).

TABLE 3C Test Test Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 10 11 Ingredients % % % % % % % % % % % Biomass 0 10 20 30 40 50 60 70 80 90 100 Mix (50/50) Fuel Blend 100 90 80 70 60 50 40 30 20 10 0 (50/50) BD 55.06 52.59 50.12 47.64 45.172 42.70 37.26 31.82 26.38 20.94 15.50 lbs/ftcubic (Wet) BTU/lb 16000.00 17471.60 16443.20 15414.80 14386.40 13358.00 12329.60 11301.20 10272.80 9244.40 8216.00 (Wet)

From the foregoing Tables 3A-3C, it can be seen that the highest energy content is provided when the proportion of the fire starter mixture 22 that is the biomass component 26 is the lowest. However, it has been determined that as a practical matter, these formulations of the fire starter mixture 22 are too wet for convenient packaging, i.e., positioning the predetermined amount of the fire starter mixture 22 in the pouch “P”. Similarly, the formulations of the fire starter mixture 22 at the other extreme (high biomass content, and very low fuel component content) are not satisfactory due to difficulties in packaging the relatively dry mixture, i.e., positioning the predetermined amount of the fire starter mixture 22 in the pouch “P”.

It can be seen in Tables 3A-3C that the energy content of the fire starter mixture 22 is relatively high when the fire starter mixture 22 includes between about 40% and about 60% of the biomass component 26, and between about 60% and about 40% of the fuel component 28.

From the foregoing Tables 3A-3C, the most advantageous mixture of primary and secondary fuels (i.e., when combined with a biomass component 26 that includes 50% coffee grounds and 50% cellulosic material) appears to be the mixture of approximately 50% C14 and approximately 50% of recovered/recycled corn oil (RCOil) respectively (Table 3A). This formulation of the fire starter mixture 22, for convenience, is referred to hereinafter as formulation “A”.

In Tables 3A-3C, the focus is on the energy contents of the various formulations listed. As noted above, due to the need to conveniently package the fire starter mixture 22, it appears that the optimum formulation(s) are mid-range formulations, rather than the formulations in which there is a preponderance of either the fuel component or the biomass component. As described below, however, when other factors are considered, a slightly different formulation of the fire starter mixture 22 may be optimal, depending on conditions.

It has also been determined that, where the biomass component 26 includes only cellulosic material, satisfactory results may be obtained. Certain test results in which formulations with only cellulosic material in the biomass component 26 were tested are set out in Tables 4A and 4B below.

Information about performance of the fuel can be found in Tables 4A and 4B. In Table 4A, the fuel component 28 is 50% C14 (the primary fuel), and 50% recovered corn oil (the secondary fuel).

TABLE 4A Test Test Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 10 11 Ingredients % % % % % % % % % % % Cellulose 0 10 20 30 40 50 60 70 80 90 100 (FP/CB/WP) Fuel Blend 100 90 80 70 60 50 40 30 20 10 0 (50/50 C14/RCO) BD 47.82 46.57 45.32 44.07 42.82 41.58 36.36 31.148 25.932 20.716 15.50 lbs/ftcubic (Wet) BTU/lb 21000.00 19550.00 18100.00 16650.00 15200.00 13750.00 12300.00 10850.00 9400.00 7950.00 6500.00 (Wet)

The data for the mixtures tested shows that between 10% cellulose and 90% fuel component, and 90% cellulose and 10% fuel component had acceptable energy content. However, as noted above, for the purposes of packaging, below 40% cellulose is too wet, and above 60% cellulose is too dry.

In Table 4B, the results shown are for a fuel component 28 including 50% kerosene (the primary fuel) and 50% recovered corn oil (the secondary fuel).

TABLE 4B Test Test Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 10 11 Ingredients % % % % % % % % % % % Cellulose 0 10 20 30 40 50 60 70 80 90 100 (FP/CB/WP) Fuel Blend 100 90 80 70 60 50 40 30 20 10 0 (50/50) BD 50.44 49.37 48.29 47.218 46.144 45.07 39.156 33.242 27.328 21.414 15.50 lbs/ftcubic (Wet) BTU/lb 20250.00 18875.00 17500.00 16125.00 14750.00 13375.00 12000.00 10625.00 9250.00 7875.00 6500.00 (Wet)

Depending on the relative availability of coffee grounds and the cellulosic material, it may be cost-effective to use only the cellulosic material in the fire starter mixture 22.

In Table 5A, test results for different blends of coffee grounds and the cellulosic material are set out.

Because 50% coffee grounds and 50% cellulosic material appears to be optimal, based solely on energy content and packaging convenience, the 50/50 blend of the biomass component was used in the results set out in Tables 5C-5D, i.e., in the results shown in Tables 5B-5D, the biomass component is 50% coffee grounds, and 50% cellulosic material.

TABLE 5A Ingredients Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 Test 10 Test 11 Biomass Mix % % % % % % % % % % % Coffee 0 10 20 30 40 50 60 70 80 90 100 Grounds Cellulose 100 90 80 70 60 50 40 30 20 10 0 (FP) BD 7.80 10.26 11.16 12.23 13.54 15.50 17.21 19.90 23.61 29.00 31.90 lbs/ftcubic (Dry) BTU/LB 7000.00 7988.80 8045.60 8102.40 8159.00 8216.00 8272.80 8329.60 8386.40 8443.20 8500.00 Dry

The fuel component 28 in Table 5B is 50% C ethanol (the primary fuel) and 50% recovered corn oil (the secondary fuel).

TABLE 5B Test Test Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 10 11 Ingredients % % % % % % % % % % % Biomass 0 10 20 30 40 50 60 70 80 90 100 Mix (50/50) Fuel Blend 100 90 80 70 60 50 40 30 20 10 0 (50/50) BD 50.19 41.58 15.15 lbs/ftcubic (Wet) BTU/lb 12800.00 16031.00 15163.20 14294.80 13426.40 12558.00 11689.00 10821.20 9952.00 9084.00 8216.00 (Wet)

The fuel component 28 in Table 5C is 50% Methanol (the primary fuel) and 50% recovered corn oil (the secondary fuel).

TABLE 5C Test Test Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 10 11 Ingredients % % % % % % % % % % % Biomass 0 10 20 30 40 50 60 70 80 90 100 Mix (50/50) Fuel Blend 100 90 80 70 60 50 40 30 20 10 0 BD 48.15 47.53 46.92 46.30 45.69 45.07 39.09 33.102 27.11 21.13 15.15 lbs/ftcubic (Wet) BTU/lb 9837.00 9837.00 14698.25 13978.00 13257.75 11817.00 11097.00 10376.70 9656.50 8936.25 8216.00 (Wet)

The fuel component 28 in Table 5D is 50% isopropanol (the primary fuel) and 50% recovered corn oil (the secondary fuel).

TABLE 5D Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 Test 10 Test 11 Ingredients % % % % % % % % % % % Biomass 0 10 20 30 40 50 60 70 80 90 100 Mix Fuel Blend 100 90 80 70 60 50 40 30 20 10 0 BD 49.50 48.14 46.78 45.42 44.06 42.70 37.19 31.68 26.17 20.66 15.15 lbs/ftcubic (Wet) BTU/lb 12960 16103.6 15227.2 14350.8 13474.40 12598.00 11721.60 10845.20 9968.80 9092.40 8216.00 (Wet)

Bulk densities are, to an extent, affected by the particle sizes of the materials of the biomass component 26. In one embodiment, the coffee grounds vary from about 100 microns to about 700 microns. The particle size distribution of the cellulosic material also depends on the screens used to screen such material. It has been found that a 30 mesh screen (Standard U.S.) may be suitable for screening the cellulosic material.

It will be understood that a wide range of bulk densities of the fire starter mixture 22 of the invention may be suitable. In general, the bulk density preferred should not be too low or too high, to facilitate packaging.

From the foregoing Tables 5B-5D, it can be seen that, in general, the highest energy content was achieved with the fuel component 28 comprising about 90% or 80% of the fire starter mixture 22, and the biomass component 26 comprising about 10% or 20% of the fire starter mixture 22. However, as noted above, for convenience of packaging, it is preferred as a practical matter that the biomass component 26 varies from approximately 60% to approximately 40%, and the proportions of the fuel component also vary accordingly.

However, as noted above, when other ways of assessing the performance of the fire starter mixture 22 are considered, a particular formulation appears to be optimal.

At present, it appears that the fire starter mixture 22 having approximately 60% biomass component 26 and approximately 40% fuel component 28 (by weight of the fire starter mixture) is preferable. In this formulation the biomass component 26 and the fuel component 28 preferably are made up of various materials as follows:

-   -   (a) biomass component: approximately 70% cellulose, and         approximately 30% coffee grounds, by weight of the biomass         component; and     -   (b) fuel component: approximately 70% primary fuel, and         approximately 30% secondary fuel, by weight of the fuel         component.

-   For example, the primary fuel may be C14, and the secondary fuel may     be recycled and recovered vegetable oil. This formulation of the     fire starter mixture 22, for convenience, is referred to hereinafter     as formulation “B”.

In one embodiment, the primary fuel may be approximately 7.5% C12-C18 and approximately 92.5% biodiesel. The secondary fuel preferably is recovered corn oil. However, those skilled in the art would appreciate that the relative costs of the different inputs may vary from time to time, so that different formulations may be preferred for cost reasons at different times.

When the foregoing formulation “B” was tested, ignition of the fire starter assembly 33 was effected within approximately 35 seconds. The flames from the fire starter mixture 22 while it burned were relatively high (approximately 14 to 15 inches), and the fire starter assembly 33 burned for about 15 minutes.

In contrast, the fire starter assembly 33 including the fire starter mixture 22 of formulation “A” had an ignition time of approximately 60 seconds. The flames were about 10 to 12 inches high, and lasted for about 20 to 25 minutes.

From the foregoing, it can be seen that, depending at least in part on the type of the solid combustible fuel “F” to be ignited and its condition, either of formulations “A” or “B”, or other formulations, may be considered optimal. It is believed that in most circumstances, and assuming that the solid combustible fuel is relatively dry, the fire starter mixture 22 having formulation “B” would be preferred.

Those skilled in the art would appreciate that the fuels (primary and secondary) may be provided in liquid form or in gel form. Although the fuels were tested in liquid form as described above, it will be understood that they may, alternatively, be used in gel form. The liquids were homogenized as emulsions with appropriate wetting agents and emulsifiers.

The cost of the fire starter mixture 22 of the invention (e.g., in dollars per BTU) is relatively low. This is, in part, due to the use of certain materials in the fire starter mixture that otherwise would be discarded, e.g., dumped at a landfill site. Accordingly, to the extent that the fire starter mixture 22 includes materials that would otherwise be discarded, it is environmentally friendly and sustainable.

It is preferred that the waste material 140 (excluding miscellaneous garbage) is processed as schematically illustrated in FIG. 2. It will be understood that miscellaneous items (i.e., materials that are not coffee grounds, moisture, or cellulosic material) that may be found in the raw waste material as received from the source may be first removed, by any suitable pre-screening method. Those skilled in the art would be aware of suitable pre-screening methods, and it is therefore unnecessary to describe pre-screening apparatus and methods in detail.

After pre-screening, the waste material 140 preferably is dried in a dryer 148 so that the moisture content thereof is less than about 10% by weight. It will be understood that the dryer preferably is any suitable dryer. Because those skilled in the art would be aware of suitable dryers, it is unnecessary to describe the dryer 148 further herein.

Once dried to a predetermined extent as described above, the dried waste material is screened on one or more screens 150 (FIG. 2). Preferably, the coffee grounds 142 are separated from the filter paper and the cups 144 by the screens 150. Any suitable screens may be used. Those skilled in the art would be aware of suitable screens. For example, it has been found that a screen of 30-40 mesh may be used to separate the coffee grounds 142 (which pass through the screen) from the filter paper 144 and the cups 146, which do not pass therethrough.

The dried coffee grounds 142 typically have an energy content of between approximately 7,500 BTU/lb. and approximately 8,500 BTU/lb. Once dried as described above, the coffee grounds 142 have a bulk density between approximately 25 lbs. per cubic foot and approximately 35 lbs. per cubic foot.

Preferably, the cellulosic material is ground to a suitable size distribution. It is believed that, depending on the composition of the fire starter in which the cellulosic material is included, a variety of size distributions of the cellulosic material may be suitable. For example, it has been found that cellulosic material passing a ⅛ inch screen is suitable. Such cellulosic material has a bulk density between approximately 7.0 lbs. per cubic foot and approximately 9.0 lbs. per cubic foot.

After the coffee grounds 142 and the cellulosic material 144 have been separated as described above, they may be stored separately for blending with the fuel component 28. As described above, the fuel component 28 preferably includes both a primary fuel and a secondary fuel. This approach is intended to result in a more economic fuel component.

As illustrated in FIG. 2, in one embodiment, plastic lids 152 preferably are removed from the filter paper and cups 144, e.g., by a suitable processor 154 (a granulator). The plastic lids 152 may be recycled.

The coffee grounds 142 and the processed filter paper and cups 144′ exiting the processor 154 (i.e., with the plastic lids 152 removed) are then measured, with the fuel component 28, on a suitable scale 156. It will be understood that the proportions of the coffee grounds 142, the processed filter paper and cups 144′, and the fuel component 28 may vary over the ranges set out above. Once the suitable amounts of these items have been measured (i.e., weighed), they are placed into a mixer 158 for mixing. As illustrated in FIG. 2, the fire starter mixture 22 is produced from the mixer 158. The fire starter mixture 22 preferably is packaged in a packaging step 34 to produce the fire starter assembly 33, as described above.

In one embodiment, it is preferred that the fuel component 28 includes at least about 10% and at most about 90% by weight of a primary fuel and at least about 10% and at most about 90% by weight of a secondary fuel.

In addition, in one embodiment, it is preferred that the primary and secondary fuels have different flash points. For example, in one embodiment, the primary fuel comprises at least about 10% and at most about 100% by weight of a non-polar fuel having a flash point less than 150° F. and at least about 10% and at most about 100% by weight of a polar fuel having a flash point less than 100° F.

Those skilled in the art would appreciate that, when mixed together to form an emulsion, the non-polar and polar fuels tend to separate from each other relatively quickly. That is, when polar and non-polar fuels are mixed together, the resulting mixture is not homogeneous, due to their tendencies to separate, depending on the hydrophilic-lipophilic balance (HLB). Accordingly, in one embodiment, it is preferred that the polar fuel and the non-polar fuel are mixed together with a non-anionic emulsifier. The non-anionic emulsifier combines a high HLB with a low HLB to provide a stable, homogeneous fuel blend, and acts as a wetting agent thereby increasing the overall combustibility of the fire starter.

In another embodiment (formulation “A”), the biomass component preferably consists of approximately 50% by weight coffee grounds and approximately 50% by weight cellulosic material, and the fuel component preferably consists of 50% by weight primary fuel and 50% by weight secondary fuel. Because the biomass component and the fuel component preferably each comprises about 50% by weight of the fire starter, this means that, in this embodiment, the proportions of the foregoing, relative to the fire starter, preferably are as follows:

coffee grounds: 25% by weight

cellulosic material: 25% by weight

primary fuel: 25% by weight

secondary fuel: 25% by weight

In another alternative embodiment, it is preferred that the biomass component is entirely made up of cellulosic material, as described above. As noted above, such biomass component is mixed with a suitable primary and secondary fuel blend.

As noted above, the fire starter mixture preferably has a relatively high energy content, e.g., between about 12,000 BTU per lb. and about 20,000 BTU per lb. From the foregoing, it can be seen that much of the energy content of the fire starter mixture of the invention is provided by the fuel component.

The secondary fuels preferably are combustible. Among the suitable secondary fuels are the following:

(a) lower carbon intensity feedstocks, e.g., animal fats and recycled cooking oils;

(b) fatty acid waste residues;

(c) algal residues from biodiesel conversion;

(d) biodiesel residue, e.g., metal esters;

(e) renewable fuel residues;

(f) used engine oils;

(g) used recycled vegetable oils; and

(h) vegetable pitches.

Those skilled in the art would appreciate that the examples of suitable secondary fuels listed above are relatively inexpensive.

The primary fuels preferably are flammable. As noted above, the primary fuel may be polar or non-polar, or an emulsion of both. Among suitable non-polar fuels (i.e., with a flash point less than 150° F.) are the following:

(a) linear alpha olefins (e.g., C12 to C18);

(b) deodorized kerosene;

(c) biodiesel methyl (with lowest carbon intensity); and

(d) fuel oils.

Among suitable polar fuels (i.e., with a flash point less than 100° F.) are the following:

(a) ethanol;

(b) methanol; and

(c) isopropyl alcohol.

As noted above, if the polar and non-polar fuels are mixed together in an emulsion, an emulsifier preferably is added, to maintain the emulsion. Among the non-anionic emulsifiers and wetting out agents/coupling agents that are suitable are the following:

(a) the following products produced by the Stepan Company:

-   -   (i) BIO-SOFT@N91-6 (HLB=12.4);     -   (ii) BIO-SOFT@N91-8 (HLB=13.9); and

(b) the following products produced by the Dow Chemical Company:

-   -   (i) TERGITOL™ 15-5-3 (HLB=8.0);     -   (ii) TERGITOL™ 15-5-53 (HLB=10.5);     -   (iii) TERGITOL™ NP-9 (HLB=12.9);     -   (iv) TERGITOL™ NP-9.5 (HLB=13.1);     -   (v) TERGITOL™ NP-10 (HLB=13.2);     -   (vi) TERGITOL™ NP-11 (HLB=13.5);     -   (vii) TERGITOL™ NP-12 (HLB=13.8);     -   (viii) TERGITOL™ NP-13 (HLB=13.9);     -   (ix) TERGITOL™ NP-15;     -   (x) TRITON™ X-15 (HLB=4.9);     -   (xi) TRITON™ X-35 (HLB=7.8);     -   (xii) TRITON™ X-45 (HLB=9.8).

As noted above, the non-anionic emulsifier is used to stabilize the blend of polar and non-polar fuels into a homogeneous blend. The non-anionic emulsifier acts as a coupling agent between the polar and non-polar fuels. It is believed that an oil-in-oil emulsifier with an HLB greater than 10.00 is needed. The non-anionic emulsifier also acts as a wetting agent for the biomass particles, to improve combustion.

In another alternative embodiment, the fire starter mixture may be mixed with a scent component, to provide a scented fire starter mixture. Those skilled in the art would be aware of various scent components that may be used. It is preferred that the fire starter mixture 22 and the scent component are mixed together, to form the scented fire starter mixture. It will be understood that any suitable scent essences may be used as the scent component. The scent component preferably is relatively insignificant by weight, e.g., forming about 1% or less by weight of the scented fire starter mixture. It will be understood that only a very small amount of the scent component may be sufficient. For instance, the scent component may form about 0.01% by weight of the scented fire starter mixture.

It will be appreciated by those skilled in the art that the invention can take many forms, and that such forms are within the scope of the invention as claimed. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole. 

I claim:
 1. A method of forming a fire starter mixture for use in igniting a fire, the method comprising: (a) providing a biomass component; (b) providing a fuel component comprising at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel; (c) mixing the biomass component and the fuel component together to provide the fire starter mixture, comprising: at least about 10% and at most about 90% by weight of the biomass component; and at least about 10% and at most about 90% by weight of the fuel component.
 2. The method according to claim 1 in which: the biomass component comprises about 50% by weight of the fire starter mixture; and the fuel component comprises about 50% by weight of the fire starter mixture.
 3. The method according to claim 1 in which: the biomass component comprises about 60% by weight of the fire starter mixture; and the fuel component comprises about 40% by weight of the fire starter mixture.
 4. The method according to claim 3 in which: the biomass component comprises: dried coffee grounds, forming about 30% by weight of the biomass component; cellulosic material, forming about 70% by weight of the biomass component; the fuel component comprises: the primary fuel, forming about 70% by weight of the fuel component; and the secondary fuel, forming about 30% by weight of the fuel component.
 5. The method according to claim 1 in which the biomass component is selected from the group consisting of dried coffee grounds, cellulosic material, and combinations thereof.
 6. The method according to claim 5 in which the biomass component comprises between 100% and 10% by weight of the cellulosic material, and between 0% and 90% by weight of the coffee grounds.
 7. The method according to claim 5 in which the biomass component comprises approximately 50% by weight of the dried coffee grounds and approximately 50% by weight of the cellulosic material.
 8. The method according to claim 5 in which the cellulosic material comprises filter paper and cardboard.
 9. The method according to claim 5 in which the dried coffee grounds are formed from coffee shop waste comprising coffee grounds, filter paper, and cups by: screening the coffee shop waste, to separate the coffee grounds from the filter paper and the cups; and drying the coffee grounds, to form the dried coffee grounds.
 10. The method according to claim 9 in which the filter paper and the cups are separated from each other and the separated filter paper is processed to provide the filter paper and the separated cups are processed to provide the cardboard.
 11. The method according to claim 1 in which the primary fuel comprises at least about 10% and at most about 100% by weight of a non-polar fuel having a flash point less than 150° F. and at least about 10% and at most about 100% by weight of a polar fuel having a flash point less than 100° F.
 12. The method according to claim 11 in which the polar fuel and the non-polar fuel are mixed together with a non-anionic emulsifier.
 13. The method according to claim 1 additionally comprising: (d) mixing the fire starter mixture and a scent component together to form a scented fire starter mixture, the scent component comprising about 1% or less by weight of the scented fire starter mixture.
 14. A method of forming a fire starter assembly comprising: (a) providing a fire starter mixture comprising: at least about 10% and at most about 90% by weight of a biomass component; at least about 10% and at most about 90% by weight of a fuel component, the fuel component comprising at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel; and (b) positioning the fire starter mixture in an at least partially flammable container.
 15. The method according to claim 14 additionally comprising: (c) closing the container, to enclose the fire starter mixture therein.
 16. A fire starter mixture comprising: at least about 10% and at most about 90% by weight of a biomass component; and at least about 10% and at most about 90% by weight of a fuel component, the fuel component comprising at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel.
 17. The fire starter mixture according to claim 16 in which the biomass component is selected from the group consisting of dried coffee grounds, cellulosic material, and combinations thereof.
 18. The fire starter mixture according to claim 17 in which the biomass component comprises between 100% and 10% by weight of the cellulosic material, and between 0% and 90% by weight of the coffee grounds.
 19. The fire starter mixture according to claim 17 in which the biomass component comprises approximately 50% by weight of the dried coffee grounds and approximately 50% by weight of the cellulosic material.
 20. The fire starter mixture according to claim 17 in which the cellulosic material comprises filter paper and cardboard.
 21. The fire starter mixture according to claim 16 in which the primary fuel comprises at least about 10% and at most about 100% by weight of a non-polar fuel having a flash point less than 150° F. and at least about 10% and at most about 100% by weight of a polar fuel having a flash point less than 100° F.
 22. The fire starter mixture according to claim 21 in which the polar fuel and the non-polar fuel are mixed together with a non-anionic emulsifier.
 23. A fire starter assembly comprising: a container formed of at least partially flammable material; a fire starter mixture comprising: at least about 10% and at most about 90% by weight of a biomass component; and at least about 10% and at most about 90% by weight of a fuel component, the fuel component comprising at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel, wherein a predetermined amount of the fire starter mixture is positioned in the container.
 24. A method of igniting a fire in which a solid combustible fuel is consumed, the method comprising: (a) providing the solid combustible fuel; (b) providing at least one fire starter assembly, said at least one fire starter assembly comprising: a container formed of at least partially flammable material; a fire starter mixture comprising: at least about 10% and at most about 90% by weight of a biomass component; at least about 10% and at most about 90% by weight of a fuel component, the fuel component comprising at least about 10% and at most about 90% by weight of a flammable primary fuel and at least about 10% and at most about 90% by weight of a combustible secondary fuel, wherein a predetermined amount of the fire starter mixture is positioned in the container; (c) positioning said at least one fire starter assembly at least partially below the solid combustible fuel; and (d) igniting said at least one fire starter assembly. 